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When Threads Get Screwed Up: The Madison Group
When Threads Get Screwed Up: The Madison Group
Threads in plastic parts are commonly used to assemble or fasten components. The thread geometry used for
plastic threads is commonly inherited from existing specifications used in metals. In many cases there is given
little latitude to change the thread geometry since it must conform to an already existing mating component. In
these instances, the designer may be limited to slight modifications of the geometry. However, a frequent
problem with plastic threads is not always related to the thread geometry, but rather, the design of the whole
component. After examining thousands of failures originating on threaded plastic components, this article
captures a few often forgotten, but basic aspects of plastic thread design learned over the years.
Regardless of the thread standard used, an important design aspect is to avoid sharp edges, which create stress
concentrations. A sharp geometrical transition is inherent to the root of the thread. Some standards allow
rounding or truncating the thread root up to 1/8 of the thread pitch (Figure 1). For these, the thread root should
be smoothly rounded to reduce the stress concentration. However, even after smoothing the thread root, a
stress concentration will still exist. For this reason, proper part design should consider the whole component,
not just the geometry of the thread. Factors such as wall thickness, geometry adjacent to the threads and
material selection all play a crucial role. The role of wall thickness is more obvious because it directly affects the
stress of the part, thus the stress at the thread root. Conversely, wall thickness has a less obvious effect on
processing. Thickness variations within the component can produce molded-in stresses that could further
aggravate the stress concentrating effect of the threads. Therefore, the designer must balance the unintended
consequences resulting from a specific design selection.
Rounded and
flattened truncation
alternatives to acute
angle
Rounded
thread root
Sharper thread
root as thread
terminates
The design of threads in plastic components must go beyond basic engineering standards and beyond replication
of metal threads. The geometry of the thread is an important consideration, but the design process should not
stop there. The combination of wall thickness, material properties, thread geometry and thread termination
should be considered concurrently. It is not only important to study the distribution of stresses along the
threads, but also to consider the long-term creep effects of the plastic and the residual stresses from
manufacturing.
The Madison Group has been a recognized global leader providing consulting services, technical expertise and innovative
technology to the plastics industry since 1993. What we do is simple, we solve plastic problems and find economic solutions
that help drive product development to yield higher quality parts.
Whether the problem occurs during manufacturing or during the lifetime of a product, our knowledge and technical
expertise can provide you with solutions. From consulting and technical expertise to engineering and design solutions, The
Madison Group can help!